Abstract:
This research is centred on the development of highly efficient structured magnetic circuits utilizing 3D metal printing to mitigate eddy currents. The innovative technology aims to significantly improve the efficiency and reduce the weight of electric motors and actuators, potentially transforming future motor designs.

Main objectives:

• To develop structured magnetic circuits that effectively suppress eddy currents using 3D metal printing.

• To design highly efficient electric motors and actuators through advanced additive manufacturing techniques.

Research content:
In 2017, the research team patented an innovative technology for the design of structured magnetic circuits. This breakthrough method introduces a new approach to the design and material composition of magnetic circuits, focusing on reducing energy losses, minimizing weight, and enhancing mechanical strength. The core of this method involves aligning small ferromagnetic rods along magnetic field lines, with each rod being electrically isolated from the others. This unique design is proposed to be manufactured using 3D metal printing. Given that electric motors account for an estimated 65% of global electrical energy consumption, even a modest improvement of 1% in motor efficiency could result in substantial energy savings. As a result, the development of advanced magnetic circuits through 3D metal printing is gaining rapid traction and is poised to become a cornerstone technology in the future development and production of electric motors.

The research team has already achieved significant milestones, including the development of a motor rotor using these structured magnetic circuits. This rotor demonstrated a 13% reduction in weight and an 11% decrease in moment of inertia, all while maintaining the same torque output. The rotor was manufactured from pure iron using 3D metal printing techniques. There is strong potential for further enhancements in these properties with the use of advanced materials such as FeSi or FeCo alloys.

Currently, the team is focused on advancing the design of a new generation of radial motors, incorporating this structured magnetic circuit technology. These efforts are expected to lead to substantial improvements in motor efficiency and performance, further pushing the boundaries of what is possible in modern motor design and engineering.

Publications:
KUBÍK, M.; STRECKER, Z.; ROUPEC, J.; MAZŮREK, I.; MACHÁČEK, O.; PALOUŠEK, D.; KOUTNÝ, D.; VUT v Brně: Skeleton for magnetic core and method for manufacturing the same. EP3373311, patent, 2022.

PALOUŠEK, D.; STRECKER, Z.; HUZLÍK, R.; Vysoké učení technické v Brně: Rotor with structured geometry to improve the parameters of electric rotating machines. 35254, utility model, 2021.

STRECKER, Z.; KUBÍK, M.; VÍTEK, P.; ROUPEC, J.; PALOUŠEK, D.; ŠREIBR, V. Structured magnetic circuit for magnetorheological damper made by selective laser melting technology. SMART MATERIALS & STRUCTURES, 2019, vol. 28, no. 55016, p. 1-13. ISSN: 0964-1726. http://dx.doi.org/10.1088/1361-665X/ab0b8e

Partners and Collaboration:
MGM Compro, Růžová 307, 763 02 Zlín 4, Czech Republic.

Baumüller Brno s.r.o., Skalice nad Svitavou 72, 679 01 Skalice nad Svitavou, Czech Republic.

Projects:
National Competence Centre of Mechatronics and Smart Technologies for Mechanical Engineering, Technology Agency of the Czech Republic (TA CR) – National Centres of Competence 1, TN01000071, 2019-2022.

Contact person:
Ing. Zbyněk Strecker, Ph.D.